Bakced pile fabric and method of producing the same



Jan. 19, 1965 D. w. RAHMES BACKED PILE FABRIC AND METHOD OF PRODUCING THE SAME Filed May 27. 1960 n 'Il/lll) FIBROUS WEB 6 FIBROUS WEB 6 FIG.2.

PILE LQoPs 2 .6 B .om E s w mp EE o MS. 7 R B S l SP s F EA A SL M AW B X B E T A L LATEX coAfrme LATEX coATme 5 LATEX FIBROUS WEB-REINFORCED LMINA INVENTR Donad W. Rohmes FIC-3.4

ATTORNEY United States Patent() 3,166,465 BACKED PILE FABRICAND METHQD OF f 'PRODUCHNGTHE SAME Donald W. Rahmes, Dover, Del., assigner to International Latex Corporation, Dover, Del., a corporation of Delaware Filed May 27, 196th, Ser. No. 32,207 14 Claims. (Cl. lol-66) The present invention relates to improvements in textile fabrics and ,tov a method for producing the same. More particularly, the invention relates to an improved composite structure as a backing for tufted loop or cut pile fabrics of the type used, for example, in iioor and upholstery coverings.

The invention is described with particular reference to 'floor coverings of the tufted `loop type, although it also provides improved backings for woven fabrics, either smooth `surfacedjor nap finished. Tufted carpeting is a composite structure in whichthe yarn formingthe loops or cut pile in the carpet surface is needled through the interstices of a base fabric, such as burlap. The attachment of the legs or base segments of the yarn loops to the base fabric is made more permanent by coating the underside of the base fabric with a suitable binder or adhesive, referredto as a backingcoat or back-size. In someA instances, another separate and distinct lamina or component Vof the composite structure is added in the form of what may be*V called a secondary backing to impart a greater stiffness or dimensional stability tothe floor covering. An example of a commercially used secvondary" backing is scrim, a wovenfabdric of large open meshmade of twisted paper"strands. This must be se- .backingcoaton thebarseffabri ci`b l V "fl-"he present invention advantageously provides an improvedbacking 'characterir/ied by a more compact composite structure, imparting increaseddimenslional stability to' the fabric in. all directions, and ya flexible backing'coat Y which is reinforced with a fibrous web; 'p Ihe reinforced backing'coat maintains its filexibility and resists cracking with;advantageousiyihighloadings of filler in the coating composition.

having a preformed woven base material which `the tufts are inserted,` rlda'supportin'g lamina :adhered to ing the web tov both` thebase the b'ase fabric. ,17a H v The invention also provides theadvantagefthat the improved fabrics of the invention are made by a method which requires only assingleV A application of the backing compound, which acts asan adhesive for accomplishing this multiple bonding.

i Thus, the improved'-teXtile` product Vis produced by la Jmethodwhich is relatively simple comparedV tothe slower two step process Wlienvscrimisutilized asa `secondary if 'bal'cling'for tufted carpets. i Y

j- 'By the-methodof thepresent'invention, web of Lbers;ffor`eXarnple, carpetVrayonl (acetate or viscose) bers, preferably lightly bonded, is laid on the underside of the woven base, fabric Aof a tufted carpet. Y A owable orlquid binding, agenhfor example, rubber latein .is

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used to impregnate the fibrous web such that it coats the Ifibers and penetrates through the web thereby coating the base loops of the tufts and the underside of the base fabric. Thereafter the coated laminated material is subjected to drying, and to curing conditions, if necessary, to solidify the binder thereby forming a secure bond between the base loops of the tufts and the base fabric, and forming a lamina which is a fiber-reinforced backing coat. Alternatively, the latex coating may be applied to the undersideV of the base fabric and the reinforcing web pressed into the flowable coating to lform the fiber reinforced backing lamina.

The `invention is described in greater detail with refer-y ence to the accompanying drawings which illustrate particular embodiments thereof and are not intended to con- `stitute` a limitation thereon, in which:v v FIGURE 1 is an enlarged schematic illustration of a so-called tufted carpet structure,

FIGURE 2 is a schematic view of a method for producing the articles of the'invention, and f FIGURE 3 is a schematic view of an alternative f method where the carpet is., coated Awith a backing compound andthe fibrous -web is pressed into the coating to `formed by the needling of the pile yarn through the base .cured `tothe base fabricby a separate procedure' involvl ingu-the. spreading of an adhesive ycoatfanivzl laying of the ,scrim onto the base fabric after the. backing coat-has been v 'applied.A The scrim is thusalamina separate Afrom the .l invention Aaccordihgl3-f'.is characterized `by ,an article of manufacture comprising atufted loop or. pilerfabric Y fabric interstices tothe underside 4 of the base fabric 2.

The, base 'loops 3 `are bonded to the base fabric` by means of adhesive vbinder portions 5 which have penetrated lthrough. the support lamina 20. The supportllamina 2,0 is made up essentially of two components, a web of fibers 'embedded in a matrix 7 of solidified binder.

The binder material may be an aqueous dispersion, a solution, or other suitably liquid or flowable preparation, including-hot melts in case of thermoplastic binderswhere Ythe melting `temperatures are below those which would be injurious to the fabric.

For' most applications of the invention the` binder should-,be flexible and resilient. Preferably'it is an aqueousfdisper'sion ofan elastomeric material, such as latices ,of` natural and synthetic rubber. y The latex` may be foarned, or in some cases merely agitated, to produce more loft andfa cellular structurelin thesupport lamina;'. Any ofthe `known elastomers are suitable for this purpose including natural rubber, synthetic polyisoprendf butadienestyrene, butadiene-acrylonitrile,vchloroprene,polyisobutylene and'V other types of rubbery binders. Where flexilAbility without `elasticity Willfsuffce', thermoplastic binders of. -a suitable type may be 1used, such'as .polyvinyl"clilo pride, polyvinyl acetate, acrylate resins, and acrylate-viriylV copolymers, and other lvinylcopolymers; all of which are ,well known and which of themselves form no part ofthe tity of vulcanizable elastomer.

invention; Y Mixtures-of elastomers ,and resins may be, employed as a backing coat or binderand particularly minor quantities of thermoplastic resin solidsland a major quan- Rfriflg t0 FIGURE 2,'a method tof Vproducirigithe articles offthe invention isi-illustrated in which the .fibrousv web 6,'which may be formed on conventional carding or."

garnetting machines, o r whichmaybeair deposited Vfor i more random distribution efnbersfis ferfrom m11 2r above the conveyor .22,.upon which thepil'e.` fabric 10. is

conveyed i'n an inverted position with thelbase fabric 2 exposed; :ThefwebY o is `superimposed en thepileV fabric it) in `contact with the uridersidea. gf thebase fabric -2by' saaaaas i binder layer or coating.

means of feed and combining roll 2S. The web superimposed on the fabric l is coated at 25 with a owable binding material, such as a vulcanizable rubber dispersion or latex fed through hose 27, and the coated composite is passed beneath a doctor blade or roll 28 so that the fibers in the web 6 are coated and the web saturated with the liquid binder. The binder penetrates through the loose web to coat the base loops 3 of the pile fabric and the underside of base fabric 2.

In FGURE 3, the underside 4 of base fabric 2 of the carpet is first coated with a layer 8 of binder, eg., rubber latex in the same manner as shown at 26 in FIG- URE 2. The fibrous web 6 is then pressed into the wet coating on the base fabric by combining roil 25. The latex coating penetrates the web, and the coating and web are united into a single lamina secured to the base fabric 2 and the base loops 3 of the pile fabric it). The

' coated laminate is then passed through a drying and curing oven (not shown)'where the binder is solidified and cured to provide the supporting or reinforcing lamina 20 made up of the reinforcing fibrous web 6 coated and bonded with the solid binder 7. This lamina is strongly secured to the base fabric by they binder portions which penetrate into the web and which remain integral with the binder portions permeating the web. The supporting lamina is also strongly bonded to the base loops 3 of the pile fabric on the underside of the base fabric, and the loops 3 are more tightly secured to the base fabric Z. Thisl in turn strengthens the entire structure against slipping or pulling out of the filaments forming the loops or pile, and greatly increases dimensional stability.

The fleece or web of fibers contained or embedded in the binder coating reinforces the coating. This permits utilization of greater quantities of fillers, extenders or loading agents in the binder dispersion without excessive cracking or other deterioration of the coating. This reinforcement of the coating and greater dimensional stability in the structure of the composite are advantages not limited to unwoven or tufted carpets, and therefore the invention is fully applicable to woven carpeting and other woven pile fabrics.

The flexibility or stiffness of the composite may desirably be varied not only by the choice of binder, but also by variations in the thickness of non-woven fibrous web. Also its density, weight and fiber composition may be varied to provide the composite structure with desired hand, appearance, resilience, and flexibility. The composite may be made lighter in weight and of improved dimensional stability, even with increased loading of the binding agent, compared to scrim or reticulate lamina adhesively secured to the base fabric. 1

The fibrous material may be batts or webs of a plurality of layers or cards or oriented or randomly disposed fibers made on suitable dry web-forming means, such as conventional carding or garnetting machines, or air deposited. The web mayv also be water-laid onwet-web forming devices, eg., Fourdrinier machines. The'we'bs may be made of multi-` or mono-filamentary materials,

` i.e.', yarns or threads of animal or vegetable fibers, such pulps, provided that the web orl felt is of sufficiently a porous open structure or network to permit penetration by the binder and embedding of the vweb in the binder after thelatter is solidified. Flock or loose fibers. may be used in place of a preformed web, where thefiock or loose fibers areco-deposited to provide Vaiiber-reinforced The web is preferably prebonded with any binder such as those mentioned above. This is simply to permit handling in subsequent operations and spot bonding or very small binder contents of only 5-10% are sufficient.

The length and diameter of the fibers making up the web may be widely varied whiel obtaining the advantages of the invention. Fiber lengths of above one-half inch t0 below two inches at present have given best results in terms of avoiding cracking of the coating at increased loading in the binder, and hand or appearance. The fiber diameters which at present appear particularly advantageous are from about l0 to 40 denier. It is to be understood, however, that even paper pulp fibers of much shorter length than one-half inch and other bers of diameter, e.g., 3-5 denier are usable with a lesser increase in improved properties in the composite.

The webs may also vary in weight or density, such as from below one up to several ounces per yard. It has been found that the best reinforcing properties in the binder-web lamina are found when the thickness of the web is at least equal to the thickness of the coating of binder. When this condition is observed the material exhibits a much resistance to cracking of the binder layer upon bending and fiexing of the composite fabric, even at very high loading of the binder compared to a backing coat without the reinforcing web.

The invention is further illustrated by reference to the following example which is intended to provide a complete specific embodiment of the invention.

A fibrous web consisting of carpet rayon fibers of 17 denier per lament and having a weight of approximately two ounces per square yard was laid on the underside of a jute burlap base fabric of a tufted carpet of a blend of wool and rayon yarns in the manner aboveaiescribed in connection with FIGURE 2. A quantity of carpet backing latex compound having the composition given below and with a conventionalsulfur curing system including 'accelerator was poured on the laminated material and the coating was uniformly spread across the surface of the web and pressed into the same by vmeans of a doctor blade. This procedure caused the liquid latex to penetrate the web and wet the base loops of the pile fabric and the underside of the backing, as well assubstantially filling in the interstices of the fibers in the web and thoroughly coating the bers. A strong and flexible composite did not occur.

Latex coating compound composition Constituents Parts (Dry Weight) Butadiene-styrene latex 100. Sulfur Cure System:

2 partssultur. i 5 parts Zno 10 Total.

2 parts Ethyl Zimat 1 part Zemite special (mercaptobonzothiazole) Gasein 2. Potassium oloate soap Agcrito Superlito (antioxidant) Whiting (loading or extender) Titanium dioxide (T105) (pigment loading) l. 2fl0}300 total 10 loading.

The procedure of the above example was repeated with omission of the fibrousweb of rayon fibers. The unreinforced coating cracked badly with the same 300 parts loading per parts dry rubber in the latex compound uponup from paper pulp fibers of a mean diameter of 3 denier and a mean length of 0.25 inch. Even these samples did not fail on bending the fabric as did those with unreinforced coatings with equal loading (300 parts).

Samples were prepared using 17 denier acetate fibers of mean length of 1%@ inches, and the loading in the latex binder compound was varied from 300 parts to 1000 parts. Even at 1000 parts loading there was no cracking of the backing on bending those samples in which the latex coating layer did not exceed the web thickness. Loadings of 1000 parts, however, are not generally recommended because the binder solids in the coating are then highly extended. Where the coating layer was heavier and exceeded the thickness of the web, cracking on bending was more pronounced even at 400 t0 500 parts loading.

Samples prepared with the same tufted carpet and latex backing compound using scrirn as a secondary backing were heavier and more costly, lacked desired dimensional stability on diagonal pull, and lacked desirable hand compared to the samples having :the improved composite structure of this invention. In addition, the appearance of the undern'de of carpet samples with the backing of the invention is far superior, i.e., less coarse and neater than that of scrim-backed samples. The fibrous web-reinforced latex backing coat is applicable to any fabrics for floors, walls, deck, panel, and furniture coverings, where increased hand and elimination of coating failure with loading are desired.

Various changes and modifications may be made within the scope of my invention, and the specific embodiments above-described and shown in the accompanying drawings should be regarded as illustrative only and not as a limitation on the scope of the appended claims.

What I claim:

1. An article comprising a composite textile having a finished upper surface of iilamentaly material, said material having base portions held in a base fabric, a nonwoven fibrous web contacting said base portions,` andy a mass of binder coating the ibers of said web and permeating and penetrating the interstices thereof to unite the web to said base portions and to substantially completely embed said web in a binder matrix.

2. A pile fabric with tufts held in a woven base fabric, a non-woven fibrous web engaging the underside of said base fabric, and a mass of aqueous dispersion-deposited liexible binder coating the fibers of said web and permeating the interstices thereof, said mass of binder uniting the web to said base fabric and to the base of the tufts, and forming with the fibrous web a resilient backing lamina in which the web extends throughout the thickness of the mass of binder.

3. A floor covering having a tufted surface of filamentary material with base segments thereof inserted through a woven base fabric, la non-Woven fibrous web contacting the base segments of the filaments, and a mass of flexible rubbery binder coating the fibers of said web and permeating the interstices thereof to form a fibrous web-reinforced backing coat in which the web extends throughout the thickness of the mass of binder, and a portion of said binder coating the base fabric and the base segments of the tufted filaments and uniting the web thereto and to the base fabric.

4. A oor covering according to claim 3 in which the rubbery binder is deposited from latex.

5. A woven carpet fabric having a pile surface interwoven with a base fabric, a non-woven brous web contacting the underside of said base fabric, and a mass of bi' flexible rubbery binder coated on the iibers of said web and uniting it to said basic fabric, said mass of binder forming with said web a resilient backing lamina in which the web is substantially completely embedded in said binder.

6. A woven carpet fabric according to claim 5 in which the binder is latex rubber.

7. A method of producing a composite pile fabric structure, which comprises placing a non-woven fibrous web in contact with the underside of the base material of said piie fabric, applying a flowablebinder material to said web to coat the fibers and permeate the interstices thereof, the binder penetrating to the base fabric thereby bonding the web to said base fabric and forming with the web a fiber-reinforced resilient backing lamina in which the web is substantially completely embedded in said binder.

8. A method according to claim 7 in which the binder is coated in aqueous dispersion form and the composite is dried.

9. A method according to claim 8 in which the binder is a rubber latex and after coating of the web, the composite is dried and the rubber is cured.

l0. A method of producing a composite floor covering having a tufted surface of filamentary material with base segments inserted through a woven base fabric, which comprises placing a web of non-woven fibers in contact with said base segments, applying a owable elastomeric binder to the web to coat the fibers of the web, and by penetration through the web also to coat the base segments of the iilamentary material and the underside of the base fabric, and solidifying said binder thereby bonding the web, the segments, and the base fabric into a resilient laminated structure having a fiber-reinforced iiexible backing lamina of elastomeric binder in which the web extends throughout the thickness of said binder.

ll. A method according to claim l0 in which the binder is coated an aqueous dispersion form and the coated composite is dried.

l2. A method according to claim 11 in which the binder is a rubber latex and after coating of the web, the composite is dried and the rubber is cured.

13. A method of producing a composite pile fabric, which comprises depositing a layer of flowable binder material on the underside of the base of said pile fabric, and combining with said layer a web of non-woven fibrous material to form a liber-reinforced binder lamina secured to said base, the web in said lamina extending throughout the thickness of the layer of binder.

14. A method according to claim 13 in which the base fabric is coated with a layer of latex, and the fibrous web is fully integrated into said latex layer to form a single fiber-reinforced iiexible lamina.

References Cited in the iile of this patent UNITED STATES PATENTS 1,918,849 Larson July 18, 1933 2,266,846 Buff Dec. 23, 1941 2,512,727 Rice June 27, 1950 2,550,686 Goldman May l, 1951 2,675,337 Walker et al Apr. 13, 1954 2,752,277 Keen June 26, 1956 2,787,571 Miller Apr. 2, 1957 2,948,650 Iackson Aug. 9, 1960 3,007,836 McNamara et a1 Nov. 7, 1961 3,060,072 Parlin et al Oct. 23, 1962 

1. AN ARTICLE COMPRISING A COMPOSITE TEXTILE HAVING A FINISHED UPPER SURFACE OF FILAMENTARY MATERIAL, SAID MATERIAL HAVING BASE PORTIONS HELD IN A BASE FABRIC, A NONWOVEN FIBROUS WEB CONTACTING SAID BASE PORTIONS, AND A MASS OF BINDER COATING THE FIBERS OF SAID WEB AND PERMEATING AND PENETRATING THE INTERSTICES THEREOF TO UNITE THE WEB TO SAID BASE PORTIONS AND TO SUBSTANTIALLY COMPLETELY EMBED SAID WEB IN A BINDER MATRIX. 